Battery cell



G. W. HEISE QATTERY CELL April 20, 1937.

INVENTOR Gio/Pcf IM. Hf/SE ATTORN EY Patented Apr. 20, 1937 BATTERY 'CELL George W. Heise, North Olmsted, Ohio, assignor, by mesne assignments, to Union Carbide and Carbon Corporation, a corporation of New York Application March 31, 1933, Serial No. 663,697

12 Claims.

The invention pertains in general to battery cells, such as water-activated deferred-action cells, and in particular to improvements in airdepolarized deferred-action cells, such as those disclosed in my patent application Serial No.

374,519, (now Patent No. 1,972,775, granted September 4, 1934) and also in the patent applications of Dario Domizi, Serial No. 508,788 (now Patent No. 2,051,987, granted August 25, 1936) and Serial No. 648,334 (now Patent No. 2,061,899,

granted November 24, 1936).

In cells of this type the solid electrolyte material and the water required for activation ocy cupy a volume far in excess of that of the nal solution. Heretofore it has been customary to activatev such batteries by the addition of water in two installments, rst completely fillingthe battery container, then waiting a period of hours until the level has fallen suiiiciently to permit the remainder to be added. This procedure is undesirable because itunduly defers the time when the battery is ready for service and because it necessitates detailed instructions which an inexperienced user is likely to disregard or misinterpret with injury to the battery.

The obvious expedient of increasing the height of the battery -to permit addition of all the water required at o ne time is not an adequate solution of the problem as this expedient would increase the size and cost of the carbon electrode to an undesirable extent and also unduly increase the distance which oxygen must travel from the outside air to the active electrode surface ofthe electrode, thus reducing the maximum safe current drain of the cell. Therefore, one object of this invention is to provide a battery of this type in which all of the water required for activation may be added at a single filling without increasing the distance from the outer air to the active surface fnthe electrode. T

An example of means for attaining the above object comprises raising only a portion of the battery cover to provide a-chamber having sullicient space to hold the excess water previously added in a second installment, without changing theposition of the carbon electrode. The size of the chamber in the raised portion depends upon the size of the battery and its structural features, and hence cannot be dened with exactness. The particular cells disclosed however, have an electrolyte volume of about 3.5 liters and the volume of the additional space provided is approximately After cells of this type having a raised cover I6 are activated there is a considerable volume of (Cl. 13G-112) Water above and not in intimate contact with the active` electrolyte ingredient in the cell whether loose or cast about the electrode assembly. The result is a non-uniform electrolyte solution very much diluted toward the top which 5 may penetrate the carbon electrode to a detrimental extent, and also as is Well understoodl in battery practice, cause accelerated and uneven vcorrosion of the zinc anode through the formation of concentration cells. Therefore, another 10 object is to provide such cells with means faq increasing the uniformity of concentration of the electrolyte solution in the activated battery.

Structure and production methods make it impractical to raise the main body of electrolyte in- 15 gredient suiciently to counteract this evil. I have found, however, that a small auxiliary portion of electrolyte ingredient placed above the main body and comprising perhaps one-fth to one-fourth ofthe total required in the battery will greatly increase the concentration of the electrolyte in the upper layers. Preferably, this auxiliary ingredient comprises caustic soda or other well known active material cast around a support such as the rod or Wire provided for 25 indicating the proper level of the electrolyte solution but it may, however, be cast directly in the raised portion of the cover without obstructing the filler opening, or otherwise supported in any convenient manner when in granular form. o

The uniformity of concentration of the electrolyte may vary under different conditions such as the temperature of activation and the size, position and composition of the auxiliary caustic, but the general characterof the improvement is 35 shown by the following typical examples. In batteries of this type not provided with auxiliary caustic the concentration of the electrolyte solution was approximately 50 grams of NaOH per liter one-half inch below the upper surface twen- 40 ty-four hours after activation, While normal concentration is about 230 grams per liter. In similar cells provided with auxiliary caustic cast around the indicator wire the concentration was' approximately grams per liter, while in other similar n cells with the auxiliary caustic cast directly in the cover the concentration was grams per liter. 'I'he auxiliary caustic may be ofthe same ratio of NaOH to Water as the main body of caustic, 50 but as the speed of solution'is an important factor some additional increasein concentration of the electrolyte at the top of the solution may be obtained by using an auxiliary cast of caustic having a higher NaOH to water ratio and therefore 5| -a slowerl solution rate than the main body of causd In this case the higher melting point of the tic. more concentrated caustic is not a disadvantage although it would be for the main casting since excessive heating of the carbon during casting of the caustic or subsequent battery activation ing a portion of the side wall should be avoided. Y v

When a battery of this type isused at elevated temperature or is activated with warm Water the plastic seal which encloses the carbon electrode and holds it in place may soften. Consequently, the electrode which is quite buoyant in the'elec- -trolyte solution then proceeds torise slowly through the plastic seal thus impairing the operating quality of the battery and incurring the danger of destructiveinternal short circuit. This difliculty is increased in the improved construction shown'herein because of the increased hydrostatic pressure and correspondingly greater upward thrust of the electrode. Therefore, I have provided a batterypf this type in which the car-A bon electrode' or cathode will not 'be displaced when the supporting seal becomes softenedby heat.

'I'his is attained by providing the battery with a carbon electrode having a'portion below the supporting cell-cover that is larger than the opening in the cover in which the` upper portion'of the electrode is supported.

These and other objects and novel features or the invention will be apparent from the following specification and the accompanying illustration in which:

Fig. 1 is a sideview of a two-cell battery hav.-

brolren away to A show the invention;

Fig. 2 is a topview 4of the battery shown in Fig. 1; and

Fig. 3 is a sectional view Fig. 2, showing the structureof the'upper end Aoi the carbon electrode and its relation to the cell cover. l

An example of the application of my invention as embodied in` the battery shown in the drawing comprises a battery casing IIJ provided with main chambers or compartments II and I2 for identical battery cells. Each cell is provided with two zinc'electrodes I3 and I4, a carbon electrode I5 and a main body or cast of 'solid hydrated caustic soda I6 around the electrodes belowthe nonnal solution level. This main body may be in another part of the cell and in other form such vas granular.

Each of the cell compartments II and I2 is provided with a cover II having a depending wall or portion 'I8 with a constrlcted bottom I9 provided with an opening through which the carbon electrode I5 extends upward to the outer atmosphere. A filling` of thermoplastic sealing material between the inner surface of the ldepending wall I8' and the upper end of the carbon electrode I5 normally holds itin place.

In order to prevent the carbon electrode I5 from moving upward when the `sealing material 20 has been softened by heat, the electrode is provided with a portion below the cover I1 that is larger than the opening in the cover in which the electrode is secured. Preferably, this`en` largement comprises shoulders 2I on the respective edges of the electrode that rest against or are slightly below the constrlcted portion I9 of the cover I'I. These shoulders may be of any suitable size although for convenience they extend downward the length of the electrode. Inl

' storage batteries.

alpng line 3 3 ofv other words, vthe width of the upper end of the yelectrode that is supported by the cover is reduced or slightly. narrower than the portion of the'electrode below the cover.

In order to provide room for the water re- Yquired to activate the battery a Aportion 22 of The auxiliary caustic soda may be supported at or above the liquid level in any suitable way'.

For example, it may be cast directly in the raised' portion 22 of cover I'I above the normal solution level of the cell as shown at 25 in the cover for cell compartment! 2, or it may be cast arounda support such as the level indicator wire 26 at least partially above the normal solution level as shown vat 21 in cell compartment II. When placed directly in the cover it should. be cast around the filler opening or provided with an opening 28 through which the activating water may be added. When placed around the Indicator wire 26 it is preferably cast in the form' of a cylinder extending substantially thewidth of the battery. I-I/owever,l it may be cast in other forms in either case, or supported by other suitable means when in granular form.

As further examples of applications of the invention, the auxiliary water chamber and auxiliary causticl may be applied to other cells or batteries such as copper oxide cells or alkaline Also, the solid electrolyte materialfmay comprise potassium hydroxide (KOH) as Well as sodium hydroxide (NaOH) in cells having an alkaline electrolyte, or sodium bisuliylate (NaHSpOi) in cells having an acid electro- 'Ihe main body of electrolyte material may be in any suitable form such asa cast, granular, or powdered, and it may be in any portionof the cell. 'I'he auxiliary body may also be in similar forms 7and it may be supported in a sack or perforated container or cast around, upon, or in a suitable support.

The auxiliary'water chamber may be provided by raising a portion of the cell cover or in any other way as long as it Is above the normal solution1eve1,vand it may be either a part of the een or detachable. Y d Y.

Various changes may be made in the structure and relative arrangement of the component parts, and equivalent materials may be substituted without departing` from the range of the invention or the scope of the claims. I claim:-'

havingcarbon and zinc electrodes; a cast of hydrated caustic soda around said electrodes below the normal solution level of said cell; va water chamber above the normal solution level of `said cell; and acast of caustic soda'in said chamber of higher concentrationthan that around said electrodes.

2. In an air-depolari'zed deferred-action cell having carbon and zinc electrodes; a cast of caustic soda around vvsaid electrodes; a cover for said cell having a raised vportionto provide a water chamber; and a separate cast of caustic soda in said chamber.

3; In an air-depolarized deferred-action cell having carbon and zinc electrodes and adapted 45 space than the o water,

70 bottom,

portion toprovide a water chamber; a closable filling opening in the top of said raised portion; a liquid level indicating wire below said opening;

` anda cast of caustic alkali around said wire.

4. In a water-activated deferred-action cell having electrodes; a cast of caustic soda around said electrodes; and an auxiliary water chamber above the electrolyte level of such volume that -when the cell and said chamber are filled with water to activate the cell, the height of the resultant solution will be at the proper electrolyte level for the cell.

5. The invention set forth in claim 4, in. which said electrodes are supported by a cell cover, and said cover is provided with a raised portion extending above the top of said electrode to provide said auxiliary water chamber. e

6. A water-activated galvanic cell of the deferred-action type comprising a container adapted to contain an electrolyte solution, electrodes Within said container, a main body of electrolyteforming material in solid form below the normal solution level, a separate smaller body of electrolyte-forming material at least in part above the normal solution level, and means for sealing said container whereby access of air. and moisture to said electrolyte-forming material is prevented before said cell is placed in service.

'1. A deferred-action cell, adapted for being activated by the addition of water, comprising suitable electrodes in said cell, of which one is somewhat pervious to water but substantially impervious to electrolyte, and may be rendered somewhatl` inoperative by penetration of liquid; a cast of electrolyte-forming material around said elec- 40 trodes to protect them from contact with the water of activation during the solution of said electrolyte forming material, said material being of a substance that tends to sink at the time of solution, and of which a solution occupies less separate ingredients; a water chamber above V4the normal solution level of said electrolyte having a capacity substantially equal to the difference in volume between said material and water before and after solution of. said material so that a single filling of water will produce the correct solution level in said cell; and a separate auxiliary cast of electrolyte-forming material at least partially in said chamber to increase the concentration of the upper portion of said solution at the time of activation to such an extent that it will not penetrate said pervious electrode rmaterially.

8. An air-depolarized deferred-action cell, adapted for being activated by the addition of comprising suitable electrodes in said cell of which one is pervious to air and somewhat pervious to water but substantially impervious to electrolyte, and may be rendered somewhat inoperative by penetration of liquid; a cast of electrolyte-forming material around said electrodes to protect said pervious electrode from contact with the Water of activation during solution of said material, which tends to form a solution having a lower concentration near the top than near the and a solution occupying less space than the separate ingredients; a water chamber at least partially above said pervious electrode and also above the solution level of said cell of such size that when said cell and said chamber are 75 completely filled with water the surface thereof will subside to the proper operating level during solution of said material; and a separate auxiliary cast of electrolyte-forming material smaller than the main cast around the electrodes and located at least partially in said chamber to maintain a concentration of the upper portion of said solution during activation that will not materially penetrate said pervious electrode.

9. An air-polarized deferred-action cell, adapted for activation by the addition of water, comprising suitable'electrodes of which one is a carbon electrode pervious to air and somewhat pervious to water, but substantially impervious to electrolyte at approximately normal concentration, that may be rendered somewhat inoperative by penetration of liquid; a cast of electrolyte-forming material surrounding said carbon electrode to protect it from contact with the water of activation during the formation of electrolyte which, at the time of formation, tends to have a lower concentration near the top than near the bottom thereof, and also occupies less space than the separate ingredients; a separate auxiliary cast of electrolyte-forming material somewhat smaller than said main cast located at least partially above the normal solution level of said cell to maintain a concentration of the upper portion of said solution during formation of electrolyte that will not materially penetrate said carbon electrode; and a water chamber for substantially the exact amount of water required above the normal solution level at the time of filling to produce. the correct level o electrolyte after solution of said electrolyte forming material.

10. A battery cell of the deferred-action type, adapted for activation by a 'single filling of water to a point somewhat above the normalv solution level, comprising an electrode somewhat pervious to electrolyte of low concentration but substantially impervious to electrolyte of approximately normal concentration, that may be rendered somewhat inoperativeby penetration of liquid; an electrolyte ingredient in solid form below the normal solution level which, at the time of solution, tends to form an electrolyte having a lower concentration in the upper portion; and a separate and substantially smaller portion of said ingredient above the normal solution level to maintain the concentration of the upper portion of said electrolyte above that which will materially penetrate said electrode.

ll.. A-battery cell of the deferred-action type, adapted for activation by a single filling of water, comprising an electrode somewhat pervious to electrolyte of very low concentration which may be rendered somewhat inoperative by liquid penetration; a main body of electrolyte ingredient in solid form in the main chamber of said cell that tends to form an electrolyte having a low concentration in the upper portion, and also an electrolyte of lower volume than that of the separate ingredients; an auxiliary chamber above the normal solution level connected with the main chamberv for the water required above the normal solution level at the time of activation to eiect the proper solution level of the electrolyte; and an auxiliary body of electrolyte ingredient in solid form in said auxiliary chamber to maintain the upper portion of said electrolyte during the formation thereof at a concentration that will not materially penetrate said electrode.

l2. A battery cell of the deferred-action type, adapted for activation by a filling of water, coma separate auxiliary cast oi electrolyte ingredient at substantially the solution level of said cell for maintaining the upper portion of said electrolyte at a concentration that will not materially penetrate said electrode.

" GEORGE W. Hman. 

